Lunch box



R. TUCCIO LUNCH BOX Nov. 23, 1965 2 Sheets-Sheet 1 Filed Aug. 7, 1964 IN V! N TOR MHOND E G IO United States Patent 3,219,179 LUNCH BOX Raymond Tuccio, Scotch Plains, N .J assignor of one-half to Leo Miller, Plainfield, NJ. Filed Aug. 7, 1964, Ser. No. 388,171 3 Claims. (Cl. 2064) This invention relates generally to containers, and in particular to a lunch box.

A standard item of commerce for many years has been a particular type of container known as a lunch box. This is a specialized type of carrying case generally having a compartment for sandwiches or other cold food too be taken along in the morning and subsequently eaten at lunch time. The container also usually has a generally dome-like top which defines a compartment for carrying a Thermos or vacuum bottle of the type which permits liquids to be kept hot or cold. These lunch boxes are most generally made of metal, although in the past other materials have also been used. It is of course relatively difiicult and expensive to fabricate lunch boxes from metallic materials. However in the past attempts to construct them from stiff cardboard, plastics, and other materials and combinations of materials have resulted in fairly complex and not entirely satisfactory structures. In particular, it has been difficult to fabricate a smooth dome-like top for the lunch box using materials other than metals.

Accordingly, it is a general object of this invention to provide an improved lunch box manufactured of nonmetallic materials. Another object is to provide a lunch box of this type which has a dome-like top covering the vacuum bottle compartment.

Another object of the invention is to provide an improved and simplified fiat blank from which a lunch box can be manufactured. Still another object is to provide a new way of achieving a dome-like top in a lunch box of this type. Still another object is to provide a novel shelf construction which separates the sandwich compartment from the vacuum compartment. A related object is to provide individual covers or doors for the two compartments just mentioned, as well as a novel method for securing the doors or covers in place to close off said compartments.

By way of example, the aforesaid objects may be achieved by providing a fiat lunch box blank which comprises a bottom panel, a rear and top panel connected to the bottom panel and hingeable upwardly therefrom along the fold line at a rear edge of the bottom panel, and means secured at a front edge of the bottom panel for meeting with the aforesaid rear and top panel. A pair of side panels are also connected to the bottom panel and are hingeable upwardly therefrom along fold lines at respective side edges of the bottom panel. These side panels have respective curved ends remote from the bottom panel whereby to establish a curved top profile when these side panels stand upward from the bottom panel. The rear and top panel is of sufiicient length and comprises a material sufficiently firm yet flexible to extend upward from the bottom panel over the entire upstanding height of the side panels and to bend smoothly over the entire curved top profile to form a substantially semicylindrical dome, and to extend sufliciently far over the dome to meet the means which are secured at the front edge of the bottom panel to complete the lunch box front surface. The dome portion of the rear and top panel is uninterrupted by any fold line whereby to form a smoothly merging surface without any sharp angul ar discontinuity over the top of the lunch box.

When set up, the aforesaid flat lunch box blank results in a lunch box comprising a bottom panel, a rear ice panel, and a top panel formed of a firm yet flexible material upstanding from and connected to the bottom panel, and means secured at a front edge of the bottom panel for meeting with the rear and top panel. There are also a pair of side panels upstanding from and connected to the bottom panel. These side panels have respective curved upper ends whereby to establish a curved top profile. The rear and top panel is secured to the side panels and extends over the entire height of the side panels and bends smoothly over the entire curved top profile to form a substantially semi-cylindrical dome, and extends sufficiently far over the dome to meet the means which are secured at the front edge of the bottom panel to complete the lunch box front surface. The dome portion of the rear and top panel is uninterrupted by any fold line whereby to form a smoothly merging surface without any sharp angular discontinuity over the top of the lunch box.

The lunch box may also include a shelf which divides the lunch box into a lower sandwich compartment and an upper vacuum bottle compartment. This shelf construction may contribute substantially to the structural rigidity of the lunch box as a whole, and may also serve as a fastening point for the rear and top panel when it is bent down and over the dome-like top to close the vacuum bottle compartment. In addition, the aforesaid means connected to the front edge of the bottom panel may take the form of a door for closing the lower sandwich compartment. This door may also be secured to the shelf for locking the door in position to close the sandwich compartment.

The invention briefly summarized above, as well as the objects thereof, will now be described in greater detail by reference to the following drawings:

FIG. 1 is a perspective view of the lunch box of this invention fully assembly, and with all covers and doors in the closed and locked condition;

FIG. 2 is a similar view of the same lunch box, but with both its front door and top cover unlocked and open, and with one side partly disassembled to reveal the inner details of its construction;

FIG. 3 is a plain view of the flat blank from which a major portion of this lunch box is constructed;

FIG. 4 is a plan view of the blank from which the shelf of this lunch box is constructed.

In FIG. 1 the lunch box, in completed condition, is seen to include a lower front panel 14, a right side panel 24, and a rear and top panel 16 which extends upward over the back of the lunch box (not visible in FIG. 1), over a semi-cylindrical done-like top 16a, and downward over an upper front portion 16b of the lunch box. When the lunch box is in its closed condition, both the front panel 14 and the front portion 16b, which act as closures for lower and upper compartments of the lunch box respectively, are secured in place by a lock 70 which protrudes through an opening guarded by a faceplate 72. A conventional carrying handle is mounted by means of anchoring members 82 at either end, the anchoring members being secured to the dome-like section 16a of the rear and top panel.

FIG. 2 illustrates the same lunch box with the lower front door open and the upper closure 16 also rolled back to show the interior of the lunch box. This view clearly illustrates the lower or sandwich compartment below a horizontal shelf 42. This is the compartment which is closed by the front panel or lower door 14. Above the horizontal shelf 42 is the upper or vacuum bottle compartment.

This is closed by rolling down the dome section 16a of the rear and top panel 16. In the view of FIG. 2 the left side of the lunch box is shown fully assembled, but the right side is shown in a state of partial disassembly in order to illustrate details of the lunch box construction.

These details may be more fully appreciated by first discussing the lunch box blanks of FIGS. 3 and 4. In FIG. 3 is shown a thin and flat or planar blank which is designed to be folded to form the outer shell of the lunch box of this invention. This blank includes a bottom panel 12 which forms the bottom of the assembled lunch box. A typical method of constructing such a panel would be to start with a rectangular sheet of stiff cardboard of appropriate size, and put layers of a heat sealable plastic material such as polyvinyl chloride over and under the cardboard. The plastic sheets should be somewhat larger than the cardboard so as to extend somewhat beyond all edges of the piece of cardboard. These overhanging edges of the upper and lower sheets are then heat sealed together along all four edges of the piece of cardboard. The result is a fiat plastic jacket completely enclosing the cardboard. It is this assembly of the cardboard and its plastic jacket heat sealed at the edges, which is referred to herein as a panel.

The front panel 14 which comprises the door of the lower compartment is a similar panel consisting of a cardboard back-bone with a heat sealed plastic jacket. The edges of the heat sealed plastic jackets of panels 12 and 14 are heat sealed to each other along a mutual edge 90. The result is a pair of flat, stiff panels 12 and 14 connected to each other along a fold line 90, i.e., a line along Which the two panels may be folded at right angles to each other.

The other panels which comprise the blank of FIG. 3 are all constructed in the same manner and joined to each other along their respective fold lines in the manner described. In particular, the rear and top panel 16 is connected to the bottom panel along fold line 92. The left side panel 22 and right side panel 24 are joined to the bottom panel 12 along their respective fold lines 94 and 96. A left connecting panel 18 is secured to the proximal portion of the rear and top panel 16 and a right connecting panel 20 is similarly secured to the rear and top panel along respective fold lines 98 and 100. Also, a pair of shelf holder tabs 26 and 28 are constructed in a manner similar to the panels described above, and these are connected to the side panels 22 and 24 along fold lines 160 and 162 respectively. Also connected to the side panels 22 and 24 along the respective fold lines 160 and 162 are a pair of gate tabs 30 and 32. These may simply consist of leaves of plastic material without any stiff cardboard back-bone, as their function is simply to partially block the entrance of the sandwich compartment of the lunch box to prevent too easy accidental spillage of its contents.

It should also be noted that along the rear edges of the connecting tabs 18 and 20 are respective pairs of rivet holes 120, 122 and 130, 132. Similarly, the side panels 22 and 24 have pairs of rivet holes 124, 126 and 134, 136 respectively. The shelf holder tabs 26 and 28 also have respective rivet holes 128 and 138. At the distal end of the rear and top panel is a small rectangular opening 34 to accommodate the'bolt of the lock 70. For the same purpose there is provided a small rectangular opening 36 at the distal end of the front panel 14.

It should be particularly noted that the distal ends of the side panels 22 and 24 have respective curved edges 22a and 24a. It will be appreciated that these curved ends 2211 and 24a project upwardly when the side panels 22 and 24 are folded along lines 94 and 96 respectively to stand upwardly from the bottom panel 12. In this position the curved ends 22a and 24a establish a curved top profile for the lunch box, which helps in establishing the semi-cylindrical dome 16a seen in FIG. 1.

FIG. 4 illustrates a shelf blank which forms a part of the lunch box of FIGS. 1 and 2. This blank comprises a rectangular shelf panel 42. This and the other portions of the shelf blank of FIG. 4 may also be constructed of a stifi cardboard backbone With a. heat sealed plastic jacket thereover. A rear tab 44 so constructed is connected to the shelf panel 42 along a fold line 110. This and other fold lines of the shelf blank may be made by heat sealing together the edges of the. plastic jackets of two adjacent panels or tabs. A front or shelf lip panel 46 is connected to the shelf panel along a fold line 116. In addition there are side tabs 48 and 50 which are connected to the shelf panel 42 along respective fold lines 112 and 114. Further details of construction which should be noted at this point include a pair of rivet holes 148 and 150 formed in the left side tab 48, and a similar pair of rivet holes 144 and 146 formed in the right side of the tab 50. Rivet holes 140 and 142 are located near either end of the shelf lip tab 46. This tab 46 also has a centrally located rectangular opening 52 which facilitates the mounting of the lock 70 to the lip at the front of the lunch box shelf.

In order to construct the outer shell of the lunch box from the flat blank of FIG. 3, the connecting tabs 18 and 20 are first folded up vertically from the rear and top panel 16. Next the rear and top panel is folded up vertically from the bottom panel 12. This causes the connecting panels 18 and 20 to be rotated into a horizontal position so that the edge along which the holes 120, 122 or 130, 132 are punched become the top edges of the respective panels 18 and 20. At this point, the panels 16, 18, and 20 will be approximately in the position shown in FIG. 2. Next the side panels 22 and 24 are also folded up vertically from the bottom panel 12. This causes the side panel 22 to be located flush against the outer surface of the connecting panel 18 as seen at the left in FIG. 2. When the parts of the blank are so positioned, the rivet holes and 122 of the connecting tab 18 line up with the rivet holes 126 and 124 respectively of the side panel 22. This permits the connecting tab 18 to be secured to the side panel 22 so that the side panel and the rear and top panel 16 are secured together with both standing vertically upward from the bottom panel 12.

Before rivets are actually placed, however, the shelf blank of FIG. 4 is first added to the assembly of FIG. 2. First the rear tab 44 is bent downwardly and placed against the back inside wall of the lunch box formed by the rear and top panel 16. In this position the rear tab 44 serves as a foot which braces the shelf 42 against the rear and top panel 16. The side tab 48 is folded upwardly from the shelf 42 and is placed against the inside surface of the connecting panel 18 so that the rivet holes 150 and 148 line up with the connecting tab holes 120 and 122 and the side panel holes 126 and 124 respectively. At this point rivets 60 are secured through the appropriate holes in all three of the structural members 22, 18 and 48.

The next step in the construction of the lunch box is to fold the front lip tab 46 upwardly from the shelf 42 so as to form an upwardly projecting retainer lip for the shelf. Next the left side shelf holder tab 26 is folded across the front of the shelf lip 46 so that the rivet hole 128 lines up with the rivet hole 140. Then a rivet 60 may be secured in the above holes to form an additional structural connection between the side panel 22 and the assembly of the shelf 42 and lip 46.

The right side of the lunch box as shown in FIG. 2 is seen in a disassembled condition to illustrate better the manner in which the shelf side tab 50 is folded upwardly, and then overlain by the connecting tab 20 as it is folded forwardly. Next it can be visualized that the right side panel 24 is folded upwardly overlying the connecting tab 20. The resulting configuration is then made permanent by fastening the whole together with a pair of rivets. One rivet would pass through holes 134, 130 and 144, while the other would pass through holes 136, 132, and 146. It will be further appreciated that the right shelf holder tab 28 may then be folded across the shelf lip 46 so that rivet hole 138 matches up with rivet hole 142, and this portion of the assembly can then be secured with a rivet in like manner.

As seen in FIG. 2 the shelf 42 then divides the lunch box into a lower compartment for sandwiches and an upper compartment designed and shaped to accommodate a cylindrical vacuum bottle for hot or cold liquids. In order to prevent too easy accidental spillage of the contents of the lower compartment, the flexible tabs 30 and 32 are bent perpendicularly from the side panels 22 and 24 respectively to form yieldable curtains partially closing off the sides of the doorway to the lower compartment.

In order to act as a door for the lower compartment, the front panel 14 need only be folded upwardly from the bottom panel 12. In order to secure the door 14 in its closed position, a lock mechanism 70 of conventional construction is mounted in the opening 52 of the shelf lip 46. This lock mechanism includes a base portion 70a which is secured within the opening 52 by means of crimped fastening prongs, and a rotatable locking member 70b which projects forwardly from the base 70a. When the lower front door panel 14 is in closed position the opening 36 matches up with the lock mechanism 70 and the locking member 70b projects through the opening 36. Then the rotatable lock member 70b is turned so that it is oriented perpendicularly to the major axis of the rectangular opening 36 to secure the lower front door panel 14 in its closed position. This then keeps the sandwich or other contents of the lower compartment of the lunch box safely locked in place.

It will be appreciated from FIG. 2 that the rear and top panel 16 serves a variety of functions in this lunch box construction. The proximal portion of the panel 16 rises vertically from the bottom panel 12 to form the rear wall of the lunch box. This portion of the panel 16 is firmly secured to the side panels 22 and 24 by means of the connecting tabs 18 and 20 and the rivets 60. FIG. 1 best illustrates the additional functions of the rear and top panel 16. There it is seen that this panel curves forward from its rearward location up and over the bending form which is conveniently provided by the curved upper ends 22a and 24a of the side panels. By thus curving over the top profile of the lunch box the panel 16 provides a smoothly merging continuous cover from the back wall, over the top semicylindrical dome 16a, and then forward and downward over the upper front surface 16b. In this manner a closure for the upper or vacuum bottle compartment is conveniently formed by the dome portion 16a of the rear and top panel 16. This semi-cylindrical dome shape is perfect for exactly covering over the cylindrical mass of a vacuum bottle stored within the top compartment of the lunch box and resting on the shelf 42.

Further, when the rear and top panel 16 is fully curved over the top and front of the lunch box and pressed inwardly against the shelf lip 46, or against the lower front door panel 14 if that is in closed position, the rectangular opening 34 formed in the panel 16 matches up with the locking mechanism 70. Consequently the locking member b protrudes through both the front door panel opening 36 and the rear and top panel opening 34. Thus when the locking member 70b is rotated to locking position, the top closure of the lunch box formed by the panel 16 is also secured in closed position for safe retention of the vacuum bottle in its place within the upper compartment of the lunch box.

Either of the panels 14 or 16 can be closed separately and locked by means of the mechanism 70. But normally when the lunch box is being used to carry sandwiches and a vacuum bottle or any other desired contents, both panels 14 and 16 would be closed and locked. In this case the normal procedure would be to close the lower front panel 14 first, and then close the top panel 16 thereover, subsequently turning the locking member 70b to make the entire arrangement secure. Since the outermost member would then be the rear and top panel 16, it follows that opening 34 (FIG. 3) is in direct engagement with the locking member 70b, and therefore is preferably protected by a rear metal backing plate 84 (FIG. 2) and the metal face-plate 72 (FIG. 1), both of which are secured in place by crimped prongs (not shown) in conventional manner.

It will now be appreciated that the panel 16 forms, in addition to the back wall of the lunch box, a dome-like top compartment cover 16a and the upper front wall 16b which overlaps the lower front wall 14 and cooperates in locking the lunch box. Because panel 16 has the firmness of relatively stiff cardboard, when it bends to form the dome 16a the latter merges smoothly from the rear of the lunch box, over the entire top of the lunch box, and then to the front wall 16b without any corners, folds, or other sharp angular discontinuities as in prior art attempts to form a lunch box out of non-metallic materials. This shape improves the appearance of the lunch box, and also is best adapted to the shape of a cylindrical vacuum bottle. Further, the plastic jacket over each cardboard panel makes the entire lunch box waterproof and thus immune to rain or accidental spillage in the kitchen or lunch room.

For carrying purposes the lunch box is provided with the handle and its anchoring devices 82 which are afiixed to the top of the dome portion 16a by means of prongs 86 (FIG. 2) that pierece the panel 16 and are crimped over to secure them in place. When the lunch box is lifted by the handle 80, the locking member 70b, protruding through and turned perpendicular to the opening 34, prevents the top cover 16 from opening under the stress, and thus prevents spillage of the lunch box contents.

In addition, when the lunch box is set down and the upper and lower compartment doors 16 and 14 respectively are opened, the curtains 30 and 32 prevent too easy spillage of the sandwich from the lower compartmerit below the shelf 42, while the shelf lip 46 prevents the vacuum bottle from rolling olf the shelf 42 and possibly being broken as a result.

What has been described is a preferred embodiment and is believed to be the best mode of practicing the invention, but it will be clear to those skilled in the art that modifications may be made therein without departing from the principles of the invention. Accordingly this description is intended just as an example, the scope of the invention being stated in the appended claims.

I claim:

1. A container comprising:

a bottom panel;

a pair of side panels upstanding from and connected to said bottom panel;

said side panels having respective curved upper ends whereby to establish a curved top profile;

a cross-bar secured to said side panel intermediate said bottom panel and said side panel upper ends, and extending across the front of said container;

fastening means mounted at the front of said cross-bar;

a front panel hingedly connected to said bottom panel whereby to open and close the part of said container below said cross-bar, said front panel meeting said cross-bar when in closed position and including means mating with said fastening means to secure said front panel to said cross-bar in closed position;

a rear and top panel formed of a firm yet bendable material upstanding from and connected to said bottom panel;

said rear and top panel being secured to said side panels and extending over the entire height of said side panels and bending smoothly over said entire curved top profile to form a substantially semicylindrical dome, and extending sufliciently far over said dome to meet said cross-bar to close the top of said container, said container top being openable by unbending said rear and top panel;

said rear and top panel including means mating with panel to said cross-bar in position to close said container top;

said dome being uninterrupted by any fold line whereby to form a smoothly merging surface Without any sharp angular discontinuity over said container top.

2. A container comprising:

a bottom panel;

a pair of side panels upstanding from and connected to said bottom panel;

said side panels having respective curved upper ends whereby to establish a curved top profile;

a shelf mounted intermediate said bottom panel and said side panel upper ends to divide said container into upper and lower compartments, and extending across the front of said container;

fastening means mounted at the front of said shelf;

the front panel hingedly connected to said bottom panel whereby to open and close said lower compartment, said front panel meeting said shelf when in closed position and including means mating with said fastening means to secure said front panel to said shelf in position to close said lower compartment;

a rear and top panel formed of a firm yet bendable material upstanding from and connected to said bottom panel;

said rear and top panel being secured to said side panels and extending over the entire height of said side panels and bending smoothly over said entire curved top profile to form a substantially semi-cylindrical dome, and extending sufficiently far over said dome to meet said shelf to close said upper compartment, said upper compartment being openable by unbending said rear and top panel;

said rear and top panel including means mating with said fastening means to secure said rear and top panel to said shelf in position to close said upper compartment;

said dome being uninterrupted by any fold line whereby to form a smoothly merging surface without any sharp angular discontinuity over the top of said container.

3. A container comprising:

a bottom panel;

a pair of side panels upstanding from and connected to said bottom panel;

a V 8 said side panels having respective curved upper ends whereby to establish a curved top profile;

a shelf intermediate said bottom panel and said side panel upper ends to divide said container into upper and lower compartments;

said shelf including a pair of side tabs secured to respective ones of said side panels, and further including a front lip;

said side panels each including a shelf-holder tab bent from the plane of said associated side panel to be adjacent said shelf lip;

means securing said shelf lip to each of said shelfholder tabs to secure said shelf and shelf lip in position;

fastening means mounted at the front of said shelf lip;

a front panel hingedly connected to said bottom panel whereby to open and close said lower compartment, said front panel meeting said shelf lip when in closed position and including means mating with said fastening means to secure said front panel to said shelf lip in position to close said lower compartment;

21 rear and top panel formed of a firm yet bendable material upstanding from and connected to said bottom panel;

said rear and top panel being secured to said side panels and extending over the entire height of said side panels and bending smoothly over said entire curved top profile to form a substantially semi- -cylindrical dome, and extending sufficiently far over said dome to meet said shelf lip to close said upper compartment, said upper compartment being openable by unbending said rear and top panel;

said rear and top panel including means mating with said fastening means to secure rear and top panel to said shelf lip in position to close said upper compartment;

said dome being uninterrupted by any fold line whereby to form a smoothly merging surface Without any sharp angular discontinunity over the top of said container.

References Cited by the Examiner UNITED STATES PATENTS 2,352,927 7/1944 Whitehead 206-4 THERON E. CONDON, Primary Examiner. 

1. A CONTAINER COMPRISING: A BOTTOM PANEL; A PAIR OF SIDE PANELS UPSTANDING FROM AND CONNECTED TO SAID BOTTOM PANEL; SAID SIDE PANELS HAVING RESPECTIVE CURVED UPPER ENDS WHEREBY TO ESTABLISH A CURVED TOP PROFILE; A CROSS-BAR SECURED TO SAID SIDE PANEL INTERMEDIATE SAID BOTTOM PANEL AND SAID SIDE PANEL UPPER ENDS, AND EXTENDING ACROSS THE FRONT OF SAID CONTAINER; FASTENING MEANS MOUNTED AT THE FRONT OF SAID CROSS-BAR; A FRONT PANEL HINGEDLY CONNECTED TO SAID BOTTON PANEL WHEREBY TO OPEN AND CLOSE THE PART OF SAID CONTAINER BELOW SAID CROSS-BAR, SAID FRONT PANEL MEETING SAID CROSS-BAR WHEN IN CLOSED POSITION AND INCLUDING MEANS MATING WITH SAID FASTENING MEANS TO SECURE SAID FRONT PANEL TO SAID CROSS-BAR IN CLOSED POSITION; A REAR AND TOP PANEL FORMED OF A FIRM YET BENDABLE MATERIAL UPSTANDING FROM AND CONNECTED TO SAID BOTTOM PANEL; SAID REAR AND TOP PANEL BEING SECURED TO SAID SIDE PANELS AND EXTENDING OVER THE ENTIRE HEIGHT OF SAID SIDE PANELS AND BENDING SMOOTHLY OVER SAID ENTIRE CURVED TOP PROFILE TO FORM A SUBSTANTIALLY SEMICYLINDRICAL DOME, AND EXTENDING SUFFICIENTLY FAR OVER SAID DOME TO MEET SAID CROSS-BAR TO CLOSE THE TOP OF SAID CONTAINER, SAID CONTAINER TOP BEING OPENABLE BY UNBENDING SAID REAR AND TOP PANEL; SAID REAR AND TOP PANEL INCLUDING MEANS MATING WITH SAID FASTENING MEANS TO SECURE SAID REAR AND TOP PANEL TO SAID CROSS-BAR IN POSITION TO CLOSE SAID CONTAINER TOP; SAID DOME BEING UNINTERRUPTED BY ANY FOLD LINE WHEREBY TO FORM A SMOOTHLY MERGING SURFACE WITHOUT ANY SHARP ANGULAR DISCONTINUITY OVER SAID CONTAINER TOP. 